System and method for protecting one or more pipes against corrosion and corrosion-protected pipe

ABSTRACT

A carrier pipe is protected from corrosion by being received inside a casing at a location above ground. The casing, which can be formed from a polymer, defines a gap extending around an exterior surface of the carrier pipe. In one embodiment, the gap is substantially filled with a potting material having a corrosion-resistant property. In another embodiment, a self-contained impressed current cathodic protection system is received in the gap. A pull head is installed on the carrier pipe and/or casing for pulling the pipe assembly, including carrier pipe, casing, and elements received in the gap, into an underground bore as a single unit. In some embodiments multiple pipe assemblies are pulled together into the same bore.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/620,500, entitled SYSTEM AND METHOD FOR PROTECTING ONE OR MORE PIPESAGAINST CORROSION AND CORROSION-PROTECTED PIPE and filed Jun. 12, 2017,which claims priority to U.S. Provisional Patent Application Ser. No.62/348,881, entitled CATHODIC PROTECTION SHIELDING MITIGATION INPIPELINES and filed Jun. 11, 2016, each of which is hereby incorporatedby reference in its entirety.

FIELD

This disclosure generally relates to a system and method for protectingone or more pipes against corrosion and a corrosion-protected pipe forbeing received inside a bore.

BACKGROUND

Pipelines include one or more carrier pipes that carry fluids such asoil and natural gas from a source point to an end point. Pipelines canbe very long and occasionally must extend through bores in the ground toavoid obstacles such as infrastructure improvements, buildings, bodiesof water, etc. One technique for forming bores is horizontal directionaldrilling. Forming suitable bores can be expensive. To limit drillingcosts, multiple carrier pipes in a pipeline can be installed together asa group in the same bore. A more expensive alternative is to drillseparate bores for each carrier pipe. An advantage of drilling separatebores for each carrier pipe is that conventional cathodic protectionsystems can be used without adverse cathodic shielding that typicallyoccurs when cathodically protected pipes are bundled together in asingle bore.

SUMMARY

In one aspect, a corrosion-protected pipe assembly for being pulled intoa bore comprises a carrier pipe having a first transition portion, asecond transition portion, a length extending between the firsttransition portion and the second transition portion, and a wallextending along the length having an exterior surface and an interiorsurface defining a carrier lumen. A casing receives the carrier pipe andhas a first end portion adjacent the first transition portion of thecarrier pipe, a second end portion adjacent the second transitionportion of the carrier pipe, a length extending between the first endportion and the second end portion of the casing, and a wall extendingalong the length of the casing having an exterior surface and aninterior surface extending around the exterior surface of the carrierpipe wall along the length of the casing to define a gap between theinterior surface of the casing and the exterior surface of the carrierpipe along at least a segment of the length of the casing. Pottingmaterial substantially fills said gap. A pull head mounted on thecorrosion-protected pipe assembly is configured to transmit a pullingforce to the corrosion-protected pipe assembly for pulling the pipeassembly into the bore as a unit.

In another aspect, method of installing an underground carrier pipecomprises positioning a casing over the carrier pipe while the carrierpipe is above ground such that a gap is defined between an interiorsurface of the casing and an exterior surface of the carrier pipe. Thegap is substantially filled with a potting material while the carrierpipe is above ground to form a corrosion-protected pipe assembly. Thecorrosion-protected pipe assembly is pulled into a bore.

In yet another aspect, corrosion-protected pipe assembly received in abore comprises a metal carrier pipe having a first transition portion, asecond transition portion, a length extending between the firsttransition portion and the second transition portion, and a wallextending along the length having an exterior surface and an interiorsurface defining a lumen. A polymer casing has a first end portionadjacent the first transition portion of the carrier pipe, a second endportion adjacent the second transition portion of the carrier pipe, alength extending between the first end portion and the second endportion of the casing, and a wall extending along the length of thecasing having an exterior surface and an interior surface extendingaround the exterior surface of the carrier pipe wall along the length ofthe casing to define a gap between the interior surface of the casingand the exterior surface of the carrier pipe along at least a segment ofthe length of the casing. Potting material substantially fills said gapand has at least one corrosion-resistant property selected from thegroup of corrosion-resistant properties consisting of moisturetransmission inhibitor and volatile corrosion inhibitor.

In still another aspect, a kit for protecting a carrier pipe configuredto be installed in a bore against corrosion comprises a casing having aninterior surface defining a lumen and configured for receiving thecarrier pipe in the interior lumen to define a gap between the interiorsurface and the carrier pipe received in the interior lumen. Pottingmaterial is configured to substantially fill said gap. A pull head isconfigured to be connected to the casing and to transmit a pulling forceto the casing for pulling the casing, the carrier pipe, and the pottingmaterial received in said gap simultaneously into the bore as a unit.

In another aspect, a corrosion-protected pipe assembly comprises acarrier pipe having a length and a wall extending along the lengthhaving an exterior surface and an interior surface defining a lumen. Aninner spacer extends outward from the exterior surface of the carrierpipe to an outer end along at least a portion of the length of thecarrier pipe and defines an inner spacer thickness between the exteriorsurface of the carrier pipe and the outer end of the inner spacer. Theinner spacer defines at least one inner spacer passage extending alongthe inner spacer thickness from the exterior surface of the carrier pipethrough the outer end of the inner spacer. A sacrificial anode isdisposed over the inner spacer in fluid communication with the at leastone inner spacer passage. A conductive coupling material substantiallyfills the at least one inner spacer passage and electrically couples thecarrier pipe to the sacrificial anode. An electrically insulating casingextends around the sacrificial anode, the inner spacer, and the carrierpipe along at least a portion of the length of the carrier pipe. Thecarrier pipe and the sacrificial anode are configured to be electricallycoupled to a power supply which conveys electrons from the sacrificialanode to the carrier pipe to protect the carrier pipe against corrosion.

In yet another aspect, a method of providing corrosion protection of acarrier pipe comprises disposing a sacrificial anode over the carrierpipe such that the sacrificial anode is spaced apart from an exteriorsurface of the carrier pipe in fluid communication with the exteriorsurface of the carrier pipe. A casing is positioned over the carrierpipe and the sacrificial anode such that the sacrificial anode isreceived in a gap between an interior surface of the casing and theexterior surface of the carrier pipe. At least a portion of the gap isfilled with a conductive coupling material to electrically couple thecarrier pipe to the sacrificial anode using the coupling material.

In still another aspect, a kit for protecting a carrier pipe having anexterior surface and configured to be installed in a bore againstcorrosion comprises a casing having an interior surface defining a lumenand configured for receiving the carrier pipe in the lumen to define agap between the interior surface and the carrier pipe received in thelumen. An inner spacer is configured to be disposed on the carrier pipeinside said gap and has an outer end spaced apart from the exteriorsurface of the carrier pipe when disposed on the carrier pipe. The innerspacer is configured to define at least one inner spacer passageextending from the exterior surface of the carrier pipe through theouter end of the inner spacer when the inner spacer is disposed on thecarrier pipe. A sacrificial anode is configured to be disposed on theinner spacer inside the gap in fluid communication with the at least oneinner spacer passage. A conductive coupling material is configured tosubstantially fill the at least one inner spacer passage to electricallycouple the carrier pipe to the sacrificial anode.

Other aspects will be in part apparent and in part pointed outhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an underground pipeline bore and asystem for pulling a bundle of corrosion-protected pipe assemblies intothe bore;

FIG. 2 is a fragmentary elevation of a corrosion-protected pipeassembly;

FIG. 3 is a longitudinal section of the corrosion-protected pipeassembly;

FIG. 4 is a section taken in the plane of line 4-4 of FIG. 2; and

FIG. 5 is a longitudinal section of another corrosion protected pipeassembly.

Corresponding reference characters indicate corresponding partsthroughout the drawings.

DETAILED DESCRIPTION

Referring to FIG. 1, a bundle of pipe assemblies for use in forming asegment of a pipeline that extends through a bore B in the ground G isgenerally indicated at reference number 10. In the illustratedembodiment, the bundle 10 comprises a plurality of corrosion-protectedpipe assemblies, generally indicated at 110, which are described ingreater detail below. In other embodiments, the bundle can include oneor more pipes or pipe assemblies of other types. In the bundle 10, thepipe assemblies 110 are positioned adjacent one another and connected toa drill rig DR by a chain of drill pipes DP and a drilling tool such asthe illustrated back reamer BR. As explained below, the pipe assemblies110 are configured to be pulled together into the same bore B and toform a segment of a pipeline that extends through the bore and isprotected from corrosion inside the bore.

Referring to FIGS. 2-4, an exemplary corrosion-protected pipe assembly110, which can be used in the bundle 10 or as the sole conduit in asection of a pipeline, will now be described in greater detail. Otherthan components of the pipe assembly 110 illustrated in dashed lines,the pipe assembly is shown in FIGS. 2-4 in a configuration prior tobeing pulled into the bore B. In other words, the pipe assembly 110 isgenerally shown in FIGS. 2-4 in a configuration that exists when thepipe assembly is outside of the bore B and ready for being installedinto the bore. The components of the pipe assembly 110 shown in dashedlines can, in some embodiments, be installed on the pipe assembly afterthe pipe assembly is pulled into the bore B.

The pipe assembly 110 includes an inner carrier pipe 112 having a firsttransition portion 112 a, a second transition portion 112 b, and alength extending between the first transition portion and the secondtransition portion. The carrier pipe 112 comprises a metal (e.g., steel)wall that extends along the length and has an exterior surface and aninterior surface that defines a carrier lumen 114. As is known in theart, without protection the wall of the carrier pipe 112 is subject tocorrosion, which can damage or create leaks in the installed pipeline.To protect the carrier pipe 112 against corrosion, the pipe assembly 110includes a casing, generally indicated at 116, which receives thecarrier pipe. The casing is formed from a non-corroding material such asa polymer (e.g., a polyethylene (PE) such as high density PE (HDPE)). Asexplained below, before the pipe assembly 110 is pulled into the bore B,the casing 116 is configured to receive a corrosion-resistant pottingmaterial 118 in a gap 120 defined between the casing and the carrierpipe. In the illustrated embodiment, the pipe assembly 110 is free of acathodic protection system and the corrosion protection features of thepipe assembly function without of cathodic protection. In otherembodiments, the pipe assembly 110 could include a cathodic protectionsystem in addition to one or more of the corrosion protection featuresdiscussed in greater detail below.

In general, the casing 116 has a first end portion 116 a adjacent thefirst transition portion 112 a of the carrier pipe 112, a second endportion 116 b adjacent the second transition portion 112 b of thecarrier pipe, and a length extending between the first end portion andthe second end portion of the casing. The casing 116 has an interiorsurface extending around the exterior surface of the wall of the carrierpipe 112 along the length of the casing. The interior surface of thewall of the casing 116 and the exterior surface of the wall of thecarrier pipe 112 define the gap 120 along at least as segment of thelength of the casing. In one or more embodiments, the pipe assembly 110is configured so the gap is generally annular in shape. Referring toFIG. 4, in the illustrated embodiment, a plurality of spacer rails 121are positioned in the gap 120 between the carrier pipe 112 and thecasing 116 and maintain the annular shape of the gap. As explainedbelow, the gap 120 has a radial dimension that is larger than the radialextent of the spacer rails 121 along segments of the casing 116 having arelatively large internal diameter ID1 so that the spacer rails fitwithin other segments of the casing (described more fully hereinafter)having smaller internal diameters ID2 (FIG. 3). The illustrated rails121 are formed in a suitable manner, such as by joining the rails to thecarrier pipe 112 so that they extend along its length atcircumferentially spaced apart positions. For example, the rails 121 canbe formed of PE and joined to the carrier pipe using an epoxy in certainembodiments.

In one or more embodiments, the casing 116 is formed from multiplepolymer components that are fused together to form the casing. In theillustrated embodiment, the casing 116 comprises a plurality of HDPEcasing tubes 122 arranged along the length of the casing. Each casingtube 122 has a first end portion, a second end portion, and a length L1extending between the first end portion and the second end portion. Inone or more embodiments the length L1 of at least one of the casingtubes 122 is in one embodiment at least about 15 m. The casing tubes 122are arranged in end-to-end fashion so that the first end portion of onecasing tube is located adjacent the second end portion of another casingtube. A casing coupler 124 is located between each casing tube 122 in anadjacent pair. Each casing coupler 124 has a first end portion joined tothe second end portion of an adjacent casing tube 122 and a second endportion joined to the first end portion of another adjacent casing tube.In certain exemplary embodiments, the casing couplers 124 are formedfrom a PE such as HDPE and joined to the PE casing tubes 122 by buttfusion. After fusing together the casing tubes 122 and the casingcouplers 124, the bead formed on the exterior surface of the casing isremoved to ensure the pipe assembly 110 has a smooth exterior profile.The illustrated casing coupler 124 has a length L2 extending between thefirst and second end portions that is substantially shorter than thelength L1 of the casing tubes 122.

Injection ports 126 extend radially through a middle portion of eachcoupler 124. As explained below, the potting material 118 is injected inflowable form into the gap 120 through one or more of the injectionports 126. In the illustrated embodiment, each coupler 124 defines fourcircumferentially spaced apart injection ports 126 that are sealed witha plug 128. In one or more embodiments, the plug 128 comprises anexternally threaded stopper configured to be threadably received in aninjection port 126 to seal the injection port. Plugs can have otherconfigurations in other embodiments. The thickness of the coupler 124increases and the internal diameter of the coupler decreases as thecoupler extends inward from the end portions toward the middle portionto strengthen the coupler at the injection ports 128. At the endportions, the coupler 124 has an internal diameter ID1 that is about thesame as the internal diameter of the casing tubes 122 and a thickness T1that is about the same as the thickness of the carrier tubes. Along amiddle portion, the coupler 124 has an internal diameter ID2 that issmaller than the internal diameter ID1 and a thickness T2 that is largerthan the thickness T1. The coupler 124 defines the smaller internaldiameter segments of the casing 116 in the middle portion of thecoupler. In one or more embodiments, the thickness T2 is in oneembodiment at least about 5 mm larger than the thickness T1.

Referring to FIG. 3, the pull head 130 is mounted on the pipe assembly110 for transmitting a pulling force F (e.g., applied by the drillingrig DR) to the pipe assembly for pulling the pipe assembly into the boreB as a unit. That is, the pull head 130 is used to connect the casing116 and the carrier pipe 112 for being pulled into the bore B by thesame pulling force F. More specifically, the illustrated pull head 130is configured to transmit the pulling force from the carrier pipe 112 tothe casing 116. As shown in FIG. 1, the back reamer BR is connected by aswivel 131 to a group pull head 132. The group pull head 132 is attached(e.g., welded) to each carrier pipe 112 in the group 10. Thus, thedrilling rig DR, drill pipe DP, and back reamer BR impart a pullingforce F first on the carrier pipe 112. The pull head 130 connects thecasing 116 to the carrier pipe 112 so that the carrier pipe and thecasing are pulled into the bore B conjointly as a single unit.

In the illustrated embodiment, the pull head 130 cooperates with aflange 134 joined to the carrier pipe 112 (e.g., a metal flange weldedto the carrier pipe) adjacent the first transition portion 112 a toconnect the casing 116 to the carrier pipe. The flange 134 extendsradially outward from the exterior surface of the carrier pipe wall andhas an end surface facing generally in the direction of the pullingforce F. The pull head 130 has a first end portion defining a lip 136facing in a direction opposite the pulling force F and opposing the endsurface of the flange 136. A second end portion of the pull head 130 isjoined to the first end portion 116 a of the casing 116. In oneembodiment, the pull head 130 is formed from a polymer (e.g., a PE suchas HDPE) and the second end portion is butt fused to the first endportion 116 a of the casing. The fused joint between the pull head 130and the casing 116 is strong enough to transmit the pulling force F tothe casing. As with the fused joints discussed above, the externalportions of the bead formed during fusion of the pull head joint areremoved to maintain a smooth exterior surface along the pipe assembly110. Other embodiments can use other pull head configurations withoutdeparting from the scope of the invention.

At each end portion 116 a, 116 b of the casing 116, a plug 140 a, 140 bseals the gap 120 to prevent the potting material 118 from escapingthrough the end portions of the gap. At the first end portion 116 a, theplug 140 a is positioned adjacent the end of the pull head 130 in theillustrated embodiment. In other embodiments, the pull head 130 could beconfigured to seal the first end portion of the gap 120 during pull-inand the plug 140 a could be connected directly to the end portion 116 aof the casing 116 after removing the pull head 130 when pull-in iscomplete. In the illustrated embodiment, the plug 140 a includesrock-hardened putty (broadly, a curable material) built up around thecarrier pipe 112 at the free end of the pull head 130. A portion of therock-hardened putty extends into an annular space between the lip 136 ofthe pull head 130 and the carrier pipe 112. High strength fiber mat islayered over the putty and coated with a wax that forms a rigid shell ofthe plug 140 a. Similarly, the plug 140 b includes rock-hardened puttybuilt up around the carrier pipe 112 at the end portion 116 b of thecasing 116. A portion of the rock-hardened putty extends into an annularspace between the casing end portion 116 b and the carrier pipe 112.High strength fiber mat is layered over the putty and coated with a waxthat forms a rigid shell of the plug 140 b.

A corrosion detection system, generally indicated at 150, is operativelyconnected to the carrier pipe 112 for detecting corrosion of the carrierpipe. The corrosion protection system 150 includes a plurality ofresistance coupons 152 (e.g., canary style coupons) that are made frommaterial that corrodes at least as quickly as the carrier pipe 112. Thecoupons 152 (only one is shown in the drawings) are coupled to theexterior surface of the carrier pipe 112 (e.g., using an epoxy) atspaced apart locations along the length of the carrier pipe (e.g., aboutevery 200 m along the length of the carrier pipe). Wires 154 connectedto the coupons 152 extend along the length of the carrier pipe 112inside the gap 120 and between the spacers 121. The wires 154 aresecured to the exterior surface of the carrier pipe 112 by a fastenersuch as filament tape 156. The wires 154 extend out of the gap through awiring port 158 formed in the end portion 116 b of the casing 116. Thewiring port 158 is sealed with a plug of, for example, plumbers putty.In some embodiments the wires 154 can extend out of the gap 120 throughan injection port 126 formed in the coupler 124. After the pipe assembly110 is pulled into the bore B, a conduit 160 is attached to the endportion 116 b of the casing 116 that protects the wires as they extendto a location above the ground G where they are connected to a junctionbox 162. In the illustrated embodiment, the conduit 160 includes a rigid90° bend at the casing 116 and a flexible tube (not shown) extendingfrom the 90° bend to surface of the ground G. The junction box 162connects the wires 154, and thus the coupons 152, to a resistancemeasurement device 164, which detects the resistance of the coupons andcompares it to a threshold resistance determined at the time ofinstallation. Resistance changes in response to corrosion of the coupons152 and thus corrosion of the coupons, (which is indicative of corrosiveconditions within the potted gap 120) can be detected when themeasurement device 164 detects a change in resistance.

In one or more embodiments, the potting material 118 comprises one of awax and a gel. Suitably, the potting material 118 is configured to beflowable, at least while being injected into the gap 120. The pottingmaterial 118 has at least one corrosion-resistant property. For example,certain potting materials 118 are moisture transmission inhibitors thatresist corrosion by limiting the transmission of moisture through thepotting material to the carrier pipe 112. Additionally, the pottingmaterial 118 could be a volatile corrosion inhibitor (VCI) that resistscorrosion by reacting with corrosive materials such as oxygen andchlorine to neutralize the materials before they can corrode the carrierpipe.

In one embodiment, the potting material 118 is a moisture transmissioninhibitor such as Innercoat® hot-applied wax sold by Trenton Corporationof Ann Arbor, Mich. The wax can be dielectric to inhibit the flow ofelectric current through the material, which could otherwise hastencorrosion. In addition, in some embodiments, the wax can be hydrophobicto repel moisture that would enter the gap 120 through the casing 116away from the gap before it can corrode the carrier pipe 112. In certainembodiments, the wax is injected at a relatively high temperature andhardens as it cools. Thus, when installed, potting materials of thistype 118 hold their shape and provide a relatively permanent moisturebarrier. Moreover, the dimensional stability of hardened waxes allowsthe potting material 118 to permanently cover and seal breaches in thecasing 116 that may be formed as the pipe assembly 110 is pulled intothe bore. Installed properly, it is believed that potting material 118formed by a moisture transmission inhibiting wax can have a life of morethan 40 years.

In another embodiment, the potting material 118 is a VCI gel. At fieldconditions at the site of a bore B, VCI gel is a flowable material. TheVCI gel can be injected into the gap 120 through the injection ports 126without heating the gel on site. The VCI components of the gel becomespent as they react with corrosive materials in the installed pipeassembly 110. Thus, to provide long-term corrosion protection, the VCIgel can be maintained by periodically replacing the expended VCI gelwith new VCI gel. Because the gel is flowable at field conditions, spentgel can be pumped from and new gel can be simultaneously pumped into thegap 120 while the pipe assembly 110 is installed in the bore.

Although described above in an assembled configuration ready for beingpulled into a bore B, various components of the corrosion-protected pipeassembly 110 can, prior to assembly, form a kit for forming thecorrosion-protected pipe assembly. Thus any one or more of at least thepotting material 118, the spacers 121, the casing tubes 122, the casingcouplers 124, the pull head 130, the flange 134, the plugs 140 a, 140 b,the coupons 152, the wires 154, the fasteners 156 the conduit 160, thejunction box 162, and the resistance measurement device 164 can begrouped together in a kit for providing corrosion protection to thecarrier pipe 112. Likewise, these components may be grouped with thecarrier pipe in a kit for assembling a corrosion-protected pipe assembly110.

An exemplary method of using the corrosion-protected pipe assembly 110including a process for assembling the corrosion-protected pipe assemblyfrom such a kit will now be briefly described. In the illustratedembodiment, before receiving the carrier pipe 112 inside the casing 116,a technician can secure the spacer rails 121 on the exterior surface ofthe carrier pipe 112. For example, the technician sand blasts theexterior surface of the carrier pipe 112 and hand sands the rails 121and adheres the rails onto the exterior surface using an epoxy. Inaddition, the technician can connect the corrosion detection coupons 152to the exterior surface of the carrier pipe 112 and secure the wires toextend along the length of the pipe using the filament tape 156.

With the fixed components that will ultimately be received inside thegap 120 secured in place, the technician positions the casing 116 overthe carrier pipe 112 while the carrier pipe is above ground to definethe gap 120. Specifically, the technician arranges casing tubes 122 andcasing couplers 123 in end-to-end fashion over the carrier pipe 112 inalternating sequence along the length of the carrier pipe. Thetechnician butt fuses each end of a casing coupler 124 to an adjacentend of a casing tube 122 to form the casing 116. If not preinstalled,the technician welds the flange 134 onto the transition portion 112 a ofthe carrier pipe 112. After butt fusing the casing tubes 122 andcouplers 124 together, the technician removes the external bead at eachfusion joint. The technician also fuses the pull head 130 onto the endportion 116 a of the casing in alignment with the carrier pipe so thatthe lip 136 opposingly engages the flange 134. After fusing the pullhead 130, the user removes the external bead at the fusion joint. Insome embodiments, the technician drills the injection ports 126 throughthe couplers 126 and the wire port 158 through the end portion 116 b ofthe casing 116 on site. In other embodiments, one or more of the portsis pre-drilled in the coupler 124 prior to assembly of the casing 116.

After positioning the casing 116 over the carrier pipe 112 andinstalling the pull head 130, the technician installs the plugs 140 a,140 b. The technician places uncured putty on the end of the pull head130 and the end portion 116 b of the casing 116, applies the highstrength fiber wrap over the putty, coats the material with wax, andallows the plug to cure (e.g., overnight). The wax hardens to form arigid shell of the respective plug 140 a, 140 b. With the plugs 140 a,140 b, sealing the ends of the gap 120, the technician injects thepotting material 118 into the gap through selected injection ports. Incertain embodiments, the potting material is simultaneously orsequentially injected at multiple injection ports 126 spaced apart alongthe length of the casing 116. If the potting material is a wax, thetechnician heats the wax to a less viscous and thus more flowable stateat the work site adjacent the bore B before injecting. The technicianinjects the potting material 118 into the gap 120 at the work site untilit substantially fills the gap.

In some embodiments, the technician binds the corrosion-protected pipeassembly 110 together with other corrosion protected pipe assemblies orother kinds of pipes to form the bundle 10 shown in FIG. 1. For example,the user can use zip-ties, straps, or other binding structure to bindthe pipes together in the bundle 10. It is understood that in otherembodiments, the corrosion-protected pipe assembly 110 can be used as asingle pipe to be pulled into the bore B. The group pull head 132 isfitted onto the transition portion 112 a of at least one carrier pipe112 and secured by the back reamer BR and the swivel 131 to the drillpipe DP extending through the bore B, from a first access point adjacentthe bundle 10 to a second access point adjacent the drilling rig DR.

In one embodiment, the technician drills the bore B by horizontaldirectional drilling HDD after assembling the pipe assembly 110. Inother embodiments, the bore B can be drilled before or simultaneouslywith the assembly of the pipe assembly 110. In the illustratedembodiment, the drilling rig DR is positioned at an access point to thebore B remote from the bundle 10 and pulls the bundle into the bore in apullback operation using the back reamer BR. In other embodiments, thedrilling rig could be configured to pull the bundle 10 into the bore Bin a one-pass drilling operation, in which case the drilling rig and thebundle would be positioned adjacent the same access point during pullin. The technician connects the drill pipe DP to the back reamer BR,connects the back reamer to the swivel, 132, and connects the swivel tothe bundle pull head 132. As the drilling rig DR back-reams the bore B,it simultaneously pulls the bundle or group 10 into the bore.

The group pull head 132 transmits the pulling force F to each carrierpipe 112 and flange 134 in the group 10. The flange 134 transmits thepulling force F to the lip 136 of the respective pull head 130, and thepull head transmits the pulling force to the respective casing 116.Thus, the drilling rig DR pulls the pipe assembly 110—including carrierpipe 112 and casing 116—into the bore B as a single unit. If the pipeassembly 110 is one of a plurality of pipes in a bundle 10, the drillingrig DR pulls the entire bundle conjointly into the bore B, applying thepulling force to each carrier pipe 112 using the same bundle pull head132. Each pipe assembly 110 is at least somewhat bendable along itslength so that the pipe assembly or bundle of pipe assemblies cannavigate bends in the path of the bore during pull in. After beingpulled into position, the technician installs the conduit 160 and runsthe wires 154 to the junction box 162, thereby connecting the coupons152 to the resistance measurement device. In one embodiment, thetechnician removes the pull head 130 after pulling and installs a newplug 140 a of the end portion 116 a of the casing 116.

When the pipeline is in operation, the potting material 118 and casing116 protect the carrier pipe 112 from corrosion without using cathodicprotection. If a moisture transmission inhibitor wax is used for thepotting material 118, the potting material protects the carrier pipe 112from corrosion by limiting the transmission of moisture through thepotting material to the carrier pipe. If a VCI gel is used for thepotting material 118, the potting material protects the carrier pipe 112from corrosion by reacting with corrosive materials such as oxygen andchlorine to destroy the corrosive materials in the gap 120 before theycan reach the carrier pipe. During use, the corrosion detection system150 continuously monitors for corrosion of the coupons 152 by measuringthe resistance of the coupons. If corrosion is detected by a change inresistance that exceeds a threshold, the resistance measurement devicecan provide an alarm indication that notifies a pipeline user.Occasionally, when VCI gel is used as the potting material, a technicianpumps spent gel out of the gap 120 through a port (e.g., one of theinjection ports 126) in the casing 116 and injects new replacement gelinto the gap through the port.

Referring to FIG. 5, in certain embodiments, a bundle of pipes for beingpulled into the bore B can include a corrosion-protected pipe assembly,generally indicated at 210, which comprises a self-contained cathodicprotection system 280 configured to minimize cathodic shielding withinthe bore as described below. It is understood that the pipe assembly 210could be used in a single-pipe pipeline as well as a bundled-pipepipeline. The pipe assembly 210 is similar in many respects to the pipeassembly 110 and corresponding features are given correspondingreference numbers, plus 100. Like the pipe assembly 110, the pipeassembly 210 includes a metal carrier pipe 212 and an insulating casing216 arranged relative to the carrier pipe to define a gap 220. Incertain embodiments, the casing 216 is formed from butt-fused casingtubes 222 and couplers 224 (which define injection ports 226 asdescribed above). In addition, like the pipe assembly 110, the pipeassembly 210 includes a pull head 230 fused to the casing 216 and aflange 234 that connects the pull head to the carrier pipe 212 so thatthe carrier pipe and casing are pulled together into the bore B as asingle unit as described above. The ends of the gap 220 are sealed withplugs 240 that can have the same general construction as the plugs 140a, 140 b that seal the ends of the gap 120. In one or more embodiments,the pipe assembly 220 includes a corrosion detection system akin to thecorrosion detection system 150 of the pipe assembly 110, but it is notshown in FIG. 5 to illustrate other features of the pipe assembly moreclearly.

Instead of using potting material to provide corrosion protection likethe pipe assembly 110, the pipe assembly 210 includes the self-containedcathodic protection system, generally indicated at 280. In theillustrated embodiment, the cathodic protection system 280 is animpressed current cathodic protection system comprising a rectifier 282(broadly, a power supply device) configured to be connected to an ACpower source (not shown) and to be electrically coupled to the carrierpipe 212 (at a negative terminal of the rectifier) and a sacrificialanode 284 (at a positive terminal of the rectifier). In the illustratedembodiment, the carrier pipe 212 and the sacrificial anode 284 areconnected to the rectifier 282 through a junction box 286 and wires 288that extend from above ground at the junction box into the gap 220through a conduit 260 and wiring port 258 formed in the casing 216. Forclarity, only one rectifier 282, junction box 286, and wire conduit 260is shown in FIG. 5. However, in an exemplary embodiment, a rectifier 282adjacent each transition portion of the corrosion-protected pipeassembly 210 is connected to an AC power source and coupled to the anode284 and the carrier pipe 212 through a junction box 286 connected towires 288 extending through a conduit 260 and wiring port 258 at therespective transition portion of the pipe assembly 210. As explainedbelow, the cathodic protection system 280 is configured to minimizecathodic shielding by positioning the sacrificial anode 284 inside thegap 220 between the carrier pipe 212 and the casing 216 in spaced apartrelationship with the carrier pipe. Suitably, the sacrificial anode 284can comprise a porous flexible sheet material (e.g., metal mesh such astitanium mesh composed of a metal oxide catalyst sintered to an expandedtitanium mesh substrate).

An inner spacer 290 is configured to hold the sacrificial anode 284 inspaced apart relationship with the carrier pipe 212. The inner spacer290 extends outward from the exterior surface of the carrier pipe 212 toan outer end along at least a portion of the length of the carrier pipe.In the illustrated embodiment, the inner spacer 290 extendscircumferentially around the carrier pipe 212 along substantially theentire length of the carrier pipe and the sacrificial anode 284 iswrapped around the inner spacer. The inner spacer 290 has an innerspacer thickness IST extending between the exterior surface of thecarrier pipe 212 and the outer end of the spacer. In general, the spacer290 can define one or more inner spacer passages extending along theinner spacer thickness IST from the exterior surface of the carrier pipe212 through the outer end of the inner spacer to provide fluidcommunication between the carrier pipe and the sacrificial anode 284. Inthe illustrated embodiment, the inner spacer 290 comprises porousmaterial disposed around the exterior surface of the carrier pipe. Theporous material defines a network of interconnected pores that define aplurality of passages communicating between the carrier pipe 212 and thesacrificial anode 284. In one embodiment, the spacer is formed fromporous, dielectric, flexible sheet material (e.g., Rockshield pipecoating shield, sold by Corrpro Companies, Inc., of Houston Tex.)wrapped around the carrier pipe 212 and strapped in place. Suitably, theporous flexible sheet material of the sacrificial anode 284 is wrappedaround the inner spacer 290 (broadly, disposed on the inner spacer) influid communication with the passages defined by the pores.

The sacrificial anode 284 can be taped, strapped, or otherwise fastenedin place by a structure that forms an outer spacer 292 extending betweenthe anode and the casing 216. In one embodiment, the outer spacer 292comprises porous material of the same type as the inner spacer 290wrapped around the sacrificial anode 284 and extending radially betweenthe sacrificial anode and the casing 216. In other embodiments, othertypes of outer spacers can be used. For example, in one or moreembodiments, tape such as Polyken® tape, sold by SEALFORLIFE Industriesof Stadskanaal, the Netherlands, is wrapped around the sacrificial anode284 at spaced apart locations along its length. For example, in anexemplary embodiment, spacer tape is wrapped around the sacrificialanode at positions that are longitudinally aligned with the girth weldsof the carrier pipe 212 to reinforce the anode at these locations (whichmay be stressed more than other locations during pull in). The outerspacer 292 holds the sacrificial anode 284 in spaced apart relationshipwith the casing 216, and the pores in the material provide fluidcommunication between the sacrificial anode and the casing. In otherembodiments, still other types of outer spacers could be used or theouter spacer could be omitted without departing from the scope of theinvention.

A conductive coupling material substantially fills the void space insidethe gap 220 to electrically couple the carrier pipe 212 to thesacrificial anode 284. For example, the conductive coupling material canbe a flowable fluid injected through one or more injection portions 226formed in the casing 216 to fill the pores in the inner spacer 290, theouter spacer 292, and the mesh anode 284. Exemplary conductive fluidscan include conductive gels (e.g., an electrolyte) having little or nocorrosive material contents such as chlorine. Because the pores of theinner spacer 290 fluidly communicate between the carrier pipe 212 andthe sacrificial anode 284, the conductive fluid filling the poresprovide a pathway for current to flow from the anode to the exteriorsurface of the carrier pipe. Thus, the rectifier 282 draws or impressesa current through the coupling fluid to convey electrons from thesacrificial anode 290 to the carrier pipe 212 and thereby cathodicallyprotect the carrier pipe 212 against corrosion.

Although described above in an assembled configuration, variouscomponents of the corrosion-protected pipe assembly 210 can, prior toassembly, form a kit for forming the corrosion-protected pipe assembly.Thus any one or more of at least the inner spacer 290, the sacrificialanode 284, the outer spacer 292, the wires 288, the junction box 286,the rectifier 282, the casing tubes 222, the casing couplers 224, thepull head 230, the flange 234, the plugs 240, and the conduit 260 can begrouped together in a kit for providing corrosion protection to thecarrier pipe 212. Likewise, these components may be grouped with thecarrier pipe in a kit for assembling a corrosion-protected pipe assembly210.

In one embodiment, a plurality of corrosion protected pipe assemblies210 are installed together in a bundle in the bore B. To assemble eachpipe assembly 210, the porous sheet material is wrapped around thecarrier pipe 212 and strapped in place to form the inner spacer 290. Ifdesired, before securing the inner spacer 290 to the carrier pipe 212,the technician can install a corrosion monitoring system (not shown)such as the corrosion monitoring system 150 discussed above. Afterinstalling the inner spacer 290, the technician wraps the mesh anode 284around the inner spacer and secures the anode in place. For example, inone embodiment, the technician wraps metal mesh around the inner spacer290 in lengths of about 100 m. In one embodiment, the technician securesthe sacrificial anode 284 in place with tape. The technician connectsthe wires 288 to the sacrificial anode 284 and the carrier pipe 212 andsecures the outer spacer 292 around the anode. After installing thespacers 290, 292 and the sacrificial anode 284 the technician installsthe casing 216 as described above in reference to the casing 116 andruns the wires 258 through the wiring ports 288 at each end portion ofthe casing. The technician also installs the pull head 230 and the endseals 240 in the same manner as the pull head 130 and the end seals 140a, 140 b described above. With the casing 216 installed and sealed bythe end seals 240, the technician injects the conductive fluid throughthe injection ports 226 in the casing 216 to substantially fill the voidspace in the gap 220.

After pipe assemblies 210 are assembled, the technician can strap themtogether to form a bundle. Using pull yokes on the carrier pipes 212 asdescribed above, the technician pulls the bundle into the bore B usingthe drilling rig DR. As above, the pull heads 230 connect the casings216 to the carrier pipes 212 so that each pipe assembly 210 is pulledinto the bore B as a unit. After being pulled into position, thetechnician connects the conduits 260 to each casing 216 in communicationwith the wiring ports 258 and runs the wires 288 through the conduits tothe junction boxes 286 positioned above ground. The technician connectsthe junction boxes 286 to the rectifiers 282 and connects the rectifiersto an AC current source. The rectifiers transmit DC current through thejunction box 286 and the wires 288 to impress a current through theconductive coupling fluid between the sacrificial anode 284 and thecarrier pipe 212. The current conveys electrons from the sacrificialanode 284 to the carrier pipe 212 through the coupling fluid in the gap220 to inhibit the carrier pipe from corroding. Moreover, because thecathodic protection system 280 of each pipe assembly 210 draws a currentbetween the carrier pipe 212 and the anode 284 through a space insidethe gap 220 unique to the particular carrier pipe and not a common soilenvironment with multiple carrier pipes, each cathodic protection systemis self-contained and the effects of cathodic shielding are otherwiseminimized.

OTHER STATEMENTS OF THE INVENTION

A. A kit for protecting a carrier pipe configured to be installed in abore against corrosion, the kit comprising:

-   -   a casing having an interior surface defining a lumen and        configured for receiving the carrier pipe in the interior lumen        to define a gap between the interior surface and the carrier        pipe received in the interior lumen;    -   potting material configured to substantially fill said gap; and    -   a pull head configured to be connected to the casing and to        transmit a pulling force to the casing for pulling the casing,        the carrier pipe, and the potting material received in said gap        simultaneously into the bore as a unit.

B. A kit as set forth in statement A wherein the casing comprises apolymer material.

C. A kit as set forth in statement A wherein the pull head is configuredto be connected to the carrier pipe for transmitting the pulling forcefrom the carrier pipe to the casing.

D. A kit as set forth in statement A wherein the potting material has atleast one corrosion-resistant property selected from the group ofcorrosion-resistant properties consisting of moisture transmissioninhibitor and volatile corrosion inhibitor.

E. A kit as set forth in statement A wherein the potting materialcomprises a flowable material.

F. A kit as set forth in statement A wherein the potting materialcomprises one of a wax and a gel.

G. A kit as set forth in statement A wherein the casing comprises aplurality of casing tubes, each having a first end portion and a secondend portion, and at least one casing coupler having a first end portionconfigured to be connected to the second end portion of one of theplurality of casing tubes and a second end portion configured to beconnected to the first end portion of another of the plurality of casingtubes.

H. A kit as set forth in statement G wherein the casing couplercomprises a port for injecting the potting material into the gap.

I. A kit as set forth in statement A further comprising a curablematerial configured for being positioned over an end portion of said gapand curing to form a plug that seals the end portion of said gap.

J. A kit as set forth in statement A further comprising at least onespacer configured to be positioned in the gap between the casing and thecarrier pipe.

K. A kit as set forth in claim J further comprising a sacrificial anodeconfigured to be supported on the spacer inside the gap spaced apartrelationship with the carrier pipe.

Having described the invention in detail, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

As various changes could be made in the above constructions and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description and shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. A corrosion-protected pipe assembly, the pipeassembly comprising: a carrier pipe having a length and a wall extendingalong the length having an exterior surface and an interior surfacedefining a lumen; an inner spacer extending outward from the exteriorsurface of the carrier pipe to an outer end along at least a portion ofthe length of the carrier pipe and defining an inner spacer thicknessbetween the exterior surface of the carrier pipe and the outer end ofthe inner spacer, the inner spacer defining at least one inner spacerpassage extending along the inner spacer thickness from the exteriorsurface of the carrier pipe through the outer end of the inner spacer; asacrificial anode disposed over the inner spacer in fluid communicationwith the at least one inner spacer passage; a conductive couplingmaterial substantially filling the at least one inner spacer passage andelectrically coupling the carrier pipe to the sacrificial anode; and anelectrically insulating casing extending around the sacrificial anode,the inner spacer, and the carrier pipe along at least a portion of thelength of the carrier pipe; and wherein the carrier pipe and thesacrificial anode are configured to be electrically coupled to a powersupply which conveys electrons from the sacrificial anode to the carrierpipe to protect the carrier pipe against corrosion.
 2. A pipe assemblyas set forth in claim 1 wherein the inner spacer comprises porousmaterial disposed around the exterior surface of the carrier pipe.
 3. Apipe assembly as set forth in claim 2 wherein the porous materialdefines pores, the inner spacer passage being defined by one or more ofthe pores.
 4. A pipe assembly as set forth in claim 1 wherein thesacrificial anode comprises one or more sheets of metal mesh wrappedaround the inner spacer.
 5. A pipe assembly as set forth in claim 1further comprising an outer spacer disposed between the sacrificialanode and the casing.
 6. A cathodic protection system comprising a pipeassembly as set forth in claim 1 and a power supply device electricallycoupled to the carrier pipe and the sacrificial anode thereof.
 7. Abundle of corrosion-protected pipes including a plurality of pipeassemblies as set forth in claim 1 received in a bore.
 8. A method ofproviding corrosion protection of a carrier pipe, the method comprising:disposing a sacrificial anode over the carrier pipe such that thesacrificial anode is spaced apart from an exterior surface of thecarrier pipe in fluid communication with the exterior surface of thecarrier pipe; positioning a casing over the carrier pipe and thesacrificial anode such that the sacrificial anode is received in a gapbetween an interior surface of the casing and the exterior surface ofthe carrier pipe; and filling at least a portion of the gap with aconductive coupling material to electrically couple the carrier pipe tothe sacrificial anode using the coupling material.
 9. A method as setforth in claim 8 further comprising positioning an inner spacer betweenthe sacrificial anode and the exterior surface of the carrier pipe sothat the inner spacer defines passaging for providing fluidcommunication between the sacrificial anode and the carrier pipe througha thickness of the inner spacer.
 10. A method as set forth in claim 9wherein the step of positioning the inner spacer comprises disposingporous material around the exterior surface of the carrier pipe.
 11. Amethod as set forth in claim 9 wherein the step of disposing thesacrificial anode over the carrier pipe comprises wrapping metal mesharound the inner spacer.
 12. A method as set forth in claim 8 furthercomprising positioning an outer spacer between the sacrificial anode andthe casing.
 13. A method as set forth in claim 8 further comprisingconnecting the carrier pipe and the sacrificial anode to a common powersupply.
 14. A method as set forth in claim 13 further comprisingactuating the power supply to convey electrons from the sacrificialanode through the conductive coupling material to the carrier pipe. 15.A method as set forth in claim 8 wherein the step of positioning thecasing is performed after the step of disposing the sacrificial anode.16. A method as set forth in claim 8 further comprising pulling thecarrier pipe, the sacrificial anode, and the conductive couplingmaterial into a bore after the steps of disposing the sacrificial anode,positioning the casing, and filling at least the portion of the gap. 17.A method as set forth in claim 16 wherein the step of pulling furthercomprises simultaneously pulling at least one additional pipe into thebore in a bundle with the carrier pipe, the sacrificial anode, and theconducive coupling material.
 18. A method as set forth in claim 16further comprising drilling the bore by horizontal directional drilling.19. A kit for protecting a carrier pipe having an exterior surface andconfigured to be installed in a bore against corrosion, the kitcomprising: a casing having an interior surface defining a lumen andconfigured for receiving the carrier pipe in the lumen to define a gapbetween the interior surface and the carrier pipe received in the lumen;an inner spacer configured to be disposed on the carrier pipe insidesaid gap and having an outer end spaced apart from the exterior surfaceof the carrier pipe when disposed on the carrier pipe, the inner spacerconfigured to define at least one inner spacer passage extending fromthe exterior surface of the carrier pipe through the outer end of theinner spacer when the inner spacer is disposed on the carrier pipe; asacrificial anode configured to be disposed on the inner spacer insidethe gap in fluid communication with the at least one inner spacerpassage; and a conductive coupling material configured to substantiallyfill the at least one inner spacer passage to electrically couple thecarrier pipe to the sacrificial anode.
 20. A kit as set forth in claim19 wherein the inner spacer comprises a porous flexible sheet configuredto be wrapped around the exterior surface of the carrier pipe.
 21. A kitas set forth in claim 20 wherein the porous flexible sheet definespores, the inner spacer passage being defined by one or more of thepores.
 22. A kit as set forth in claim 19 wherein the sacrificial anodecomprises metal mesh configured to be wrapped around the inner spacer.23. A kit as set forth in claim 19 further comprising an outer spacerconfigured to be disposed on the sacrificial anode inside said gap. 24.A kit as set forth in claim 19 further comprising a power supply deviceconfigured to be electrically coupled to the carrier pipe and thesacrificial anode and to impress a current between the carrier pipe andthe sacrificial anode through the conductive coupling material to conveyelectrons from the sacrificial anode to the carrier pipe to protect thecarrier pipe against corrosion.
 25. A kit as set forth in claim 19wherein the conductive coupling material comprises a flowable material.26. A kit as set forth in claim 25 wherein the casing defines aninjection port and the conductive coupling material is configured to beinjected through the injection port into the gap.